Dumontis

Building Autonomy in Continual Improvement

Transformation

On the web, there is a palpable buzz of failed or unsuccessful Lean initiatives (or organizations that fail Lean if you prefer that point of view). No wonder, to be honest, as many of these initiatives can at best be characterized as programs. And more often they are even no more than a collection of disjointed projects.

Staff is trained, external consultants are brought in – often trained by another external consultant in another company going through a similar “program” – and off we are. We start identifying waste and we might even create a current state value stream map. Enough potential to fill an action list covering several pages, and so our Lean program is born.

What a joke! In doing so, a Lean initiative will never transcend the character of being only a program: a collection of projects and actions to eliminate problems. And calling these projects and actions “kaizens” really doesn’t make it more Lean. And this is only further emphasized by pursuing the apparently required “quick wins” to win over the company’s management. What is the alternative? A system-based Lean transformation, sometimes referred to as Shikumi.(more…)

You just became the proud owner of the title “Lean (Six Sigma) Black Belt” (or any other color for that matter)? Congratulations! But what, in fact, does this exactly mean? In any case, it means you invest in yourself or the organization you work for invests in its people. Good for you. But a lot of side notes can be made about the recent, totally uncontrolled proliferation in belt colors, titles, certificates and certifying organizations related to Lean and/or Six Sigma. Does such type of Lean certification actually imply a certain competence, or is it a fool’s bargain?(more…)

We often speak about the two pillars of the Toyota or Lean system, and when doing so we think of the two well-known pillars of just-in-time (JIT) and built-in quality (jidoka). JIT thereby focuses on manufacturing only the necessary products, at the necessary time, in the necessary quantity by deploying pull flow (kanban), one piece flow and leveling. Jidoka, built-in quality, or autonomation focuses on quality control by stopping the process when abnormalities are detected based upon elements such as standardized work and visual control. But is this correct? Where is “Respect for People” in all of this?(more…)

Hoshin kanri involves the identification and deployment of various initiatives (or countermeasures) to eliminate major obstacles to reach the organization’s goal and to further improve the organization’s performance. Typically, organizations subsequently track their performance to see whether they are actually improving. In hoshin kanri these performance indicators are called “control items”. But what organizations track less is whether they are actually deploying what they set out to deploy. These so called “check items” are often missing. And exactly this is one of the key aspects in which hoshin kanri differs from traditional management-by-objectives or MBO.(more…)

“Is it really true, that we do not add any value?” People in supportive functions pose me this question quite regularly. Recently it was someone from the quality department that confronted me with this question. Coincidentally or not, the quality department plays a role in each of the three Lean initiatives that I currently accompany. All of the quality departments involved are experiencing a change in the role they play as a result of the Lean transformation their organization as a whole is going through. In anticipation of the answer to the question: although I don’t think it is the right question to ask, yes, from a Lean point of view the quality department does not add value to the product. Not even when the customer has asked for it specifically and is willing to pay for it…(more…)

Not so long ago I came across a few pictures that were posted on LinkedIn that aroused my attention. They touched upon a theme that has been slumbering in my mind for quite a while, namely that off the always returning phenomenon of the trade-off. The pictures that gad around the Internet were about good quality not being possible in combination with speedy service and a very competitive price; you can’t have it all, so it seems. A trade-off indicates an optimization problem; making the best choice considering multiple variables and their interdependence. But unfortunately, optimization assumes certain dependencies instead of challenging the thinking behind these presumed interdependencies. It’s time to get rid of the trade-off!(more…)

Lean transformations typically require interventions on both content (technical) and cultural aspects (attitude and behavior) and these together initiate and drive the required change. When assisting clients on their Lean journeys, my focus is on this triangle of content, culture and change. However, this change does not happen just because you intend it. As many have learned, people don’t change because you want them to change. But they don’t dislike change either. They just don’t like being changed. For a successful and sustainable Lean transformation, Trust (T) needs to be built between leadership, managers and the workforce, but also between any support staff or consultant and line management. Trust is required in order to be accepted as leader, coach or Lean guide.(more…)